Polymer products



Patented July 23, 1946 POLYMER PRODUCTS Ray Clyde Houtz, Snyder, N. Y., assignor to E. I.

du Pont de Nemours & Company, W

Del., a corporation oi Delaware No Drawing. Application November 4, 1944, Serial No. 562,018

Claims. (0:. zoo-o2) This invention relates to a new composition of matter and shaped articles produced therefrom. More particularly, this invention reiates to an organic solvent solution of polyacrylonitrile, i. e. polymerized acrylonitrile or polymerized vinyl cyanide (CHFCHCNlr, and copolymers and interpolymers of acrylonitrile in which at least 85% by weight of the polymer is acrylonitrile, and to the production of shaped articles from said organic solvent solution of said polymers of acrylonitrile.

This application is a continuatlon-in-part of the copending application of Ray Clyde Houtz, Serial No. 447,446, filed June 1'7, 1942.

Polyacrylonitrile, and copolymers and interpolymers of acrylonitrile with other polymerizable substances, for example vinyl or acrylic compounds, in which at least 85% by weight of the polymer is acrylonitrile have been known for some time and recognized as possessing desirable physical and chemical properties including toughness and insolubility in and insensitivity to common organic solvents such as methyl or ethyl alcohol, acetone, ethyl ether, ethyl acetate, hydrocarbon solvents, chlorinated hydrocarbons and the like. Because of these facts, numerous attempts have been made to form these polymeric materials into yarns, films and other shaped articles.

The copending application of George H. Latham, Serial No. 562,012, filed of even date herewith discloses solutions of polyacrylonitrile in dimethyl carbamyl compounds and the production of extruded and otherwise shaped articles and structures from such solutions. The abovesaid application of George H. Latham represents the first successful dissolution of polyacrylonitrile in a solvent to produce a solution which is suitable for the production of commercially useful textile yarns or wrapping tissue films and similar tough, flexible structures.

The present application relates to a similarly satisfactory dissolution of polyacrylonitrile in an organic solvent taken from a difierent class of organic compounds.

It is therefore an object of this invention to dissolve polyacrylonitrile, or a copolymer or interpolymer of acrylonitrile in which at least 85% by weight of the polymer is acrylonitrile, in a solvent which does not react with or decompose the polymer and which may be substantially (,zoiripletely removed from structures formed of was a solution.

It is another object of this invention to produce a solution of polyacrylonitrile, or a copolymer or interpoiymer oi acryionitriie in which 2 at least by weight of the polymer is acrylonitrile, in a solvent which does not react with or decompose the polymer, the solution being suitable for the formation of commercially useful, substantially void free articles of polyacrylonitrile.

It is another object of this invention to pro duce a solution of polyacrylonitrile, or a copolymer or interpolymer of acrylonitrile in which at least 85% by weight of the polymer is acrylonitrile, in a volatile organic solvent, which solution is stable over extended periods of time at room temperature or elevated temperatures.

It is a further object of this invention to produce, from solution, polyacrylonitrile, or a copolymer or interpolymer of acrylonitrile in which at least 85% by weight of the polymer is acrylonitrile in its substantially undecomposed and chemically unchanged state.

It is still another object of this invention to produce, from solution, polyacrylonitriie, or a copolymer or interpolymer of acrylonitrile in which at least 85% by weight of the polymer is acrylonitrile which is tough, flexible, tenacious and free from voids.

Other objects of the invention will appear hereinafter.

The objects of the invention may be accomplished in general by dissolving polyacrylonitrile, or a copolymer or interpolymer of acrylonitrile in which at least 85% by weight of the polymer is acrylonitriie, in an aromatic diamino compound taken from the group consisting of:

Ortlio phenylone dimino Meta phonylcne diamlne NHI Para phenylene diamine 2,2,4,4-l.etramino 5,5-dimethyl diphenyl methane 2,0-dian1lno pyridine H N' HI 2,4,0triamino toluene These acrylonltrile solutions may be formed into a shaped structure and the aromatic diamino solvent removed from the so formed structure. The solvent may be removed by evaporation under vacuum, or it may be removed by leaching the solvent from the structure by means of a liquid, for example water, which will dissolve the solvent but which is inert to the acrylonitrile structure. If desired, a structure can be formed from the solution and a portion of the solvent retained in the structure as a plasti cizer.

A number of the above-mentioned solvents become colored on exposure to air, especially at temperatures above their melting points. It is therefore desirable, if a substantially colorless product is required, to prepare the solutions and to form the structures therefrom while excluding oxidizing atmospheres. This may be done by forming the solutions and subsequently forming structures from the solutions in the presence of nitrogen gas.

The solutions are prepared by dissolving the polyacrylonitrile, or copolymer or interpolymer of acrylonitrile with one or a mixture of the above-mentioned solvents. These solvents are solid at ordinary temperatures and dissolve or retain the polymer in clear solution, sometimes only at elevated temperatures, for example at temperatures of 100 C. or higher, below which temperature the composition often resembles a gel. In all cases. when the polymer is dissolved in a solvent of the above class, the resulting composition while hot has the appearance of a true solution. When cooled to room temperature, the composition frequently takes on the appearance of a gel, which gel may on prolonged standing undergo syneresis. Reheating of this gel or gymersed mass however causes it to again return to solution form.

In view of the relatively high melting points of some of the solvents of this invention, they are useful as solvent plasticizers for polyacrylonitrile. The present invention therefore contemplates solid solutions of acrylonitrile polymers containing at least 85% by weight of acrylonitrile as well as liquid solutions thereof.

Shaped articles obtained from solvent solutions of polyacrylonitrile in accordance with the invention and from which the solvent is subsequently removed are substantially free oi foreign matter and voids and substantially undecomposed and chemically unchanged from the simple polymer prior to its solution.

The polyacrylonitrlle for use with the invention is preferably prepared by the ammonium persulfate catalyzed polymerization of monomeric acrylonitrile dissolved or emulsified in water. It can, however, be prepared by any other suitable type of polymerization reaction such as, for example, the emulsion type reaction disclosed by U. S. Patent No. 2,160,054 to Bauer et al. The polymer preferably possesses a molecular weight within the range of 15,000 to 250,000 or even higher, as calculated from viscosity measurements by the Staudinger equation:

Molecular weight= The molecular weight of the polymer obtained is dependent on such factors as the concentration of the monomer in the water, the amount and type of catalyst present, the temperature of the reaction, etc. For example, polyacrylonitrile having a molecular weight of approximately 60,000 can be prepared as follows: To 94 pounds of distilled water heated to 40 C. add 40 grams of ammonium persulfate catalyst and grams of sodium bisulflte activator. Then add 16 pounds of acrylonitrile slowly with stirring over a period of two hours. The polyacrylonitrile having the above said molecular weight will precipitate from the solution. Increasing or decreasing the amount of the catalyst, while maintaining the other conditions constant, decreases or increases the molecular weight of the polymer. Acrylonitrile copolymers and lntei'polymers containlng at least by weight of acrylonitrile and likewise preferably having a molecular weight of 15,000 to 250,000-or higher can be prepared in a similar manner.

The following example illustrates a preferred method of preparing a solution of polyacrylonitrile in accordance with the principles of this invention. The invention is not to be limited by the details set forth in the example.

Example I Ten (10) parts by weight of an acrylonitrile polymer prepared by the polymerization of monomeric acrylonitrile in accordance with the teachings of U. 8. Patent No. 2,160,054 to Bauer et a1. and possessing an average molecular weight of 120,000 are ground to an average particle size of 200 mesh and intimately mixed with parts by weight of meta-phenylene diamine ground to a similar particle size. The mixture is heated over a period of thirty minutes to a temperature of 200 C. in a closed container, in the presence of nitrogen, to form a fluid. homogeneous mass or solution. The solution may be extruded through a i5-hole spinneret at a temperature of 200 0. into 9. glycerol bath heated to 115 C. to form a l5-filament yam. A bath travel 01' 24 inches may be employed and the yarn subjected to a tension of 0.5 gram per denier (based on the final yarn denier) during its travel through the bath. The phenylene diamine is removed or leached from the yarn by the glycerol, thereby coagulating the polymer.

A above indicated, it is possible by the practice of this invention to obtain a solution of polyacrylonitrile, or a copolymer or interpolymer of acrylonitrile which may be used in the manufacture oi shaped articles such as yarns, films or molded articles. These solutions are also suited for use as lacquers or coating compositions. They are especially useful in the coating or wire and electrical parts where the high chemical and electrical resistance of the polymer is important.

As also shown, the solvents of the invention are useful not only in connection with the polyacrylonitrile, but also with copolymers and interpolymers of acrylonitrile with other polymerizable substances such as, for example, compounds containing one or more ethylenic linkages including vinyl and acrylic compounds as well as olefinic or diolefinic hydrocarbons such as isobutylene, butadiene, etc., They are eminently satisfactory for use with those polymers that contain a large amount oi acrylonitrile, for example polymers, or copolymers or interpolymers that contain at least 85% by weight of acrylonitrile and that have generally been regarded by the art as being completely insoluble in all common organic solvents. Nor are these solvents limited to use with a polyacrylonitrile of any given molecular weight. They can be used with a polymer of almost any given molecular weight and are especially satisfactory for use with those polymers having an average molecular weight within the range of 15,000 to 250,000 as determined by viscosity data using the Staudinger equation and intended for use in the manufacture of yarns or films.

The solution of acrylonitrile polymer dissolved in an organic solvent in accordance with this invention must be of such a concentration that its viscosity at the operating temperature is within a workable range. When it is to be employed in the spinning of yarn or the casting of film, the solution should preferably have a viscosity within the range of 25 to 750 pulses. When the polymer has a molecular weight or 250,000 or more, this requires that the maximum concentration of polymer in the spinning solution be of the order oi Generally. it is preferred that the spinning solution contain at least 10% 0! the polymer because of the diillculty of rapidly removing large amounts of solvent from the solution in the spinning operation. Moreover, it is economically undesirable to use such large amounts or solvent for the spinning of a given amount 01' polymer although it is true that the solvent can be completely recovered from the spinning operation and reused. For these reasons, it is preierred to employ a Polymer having an average molecular weight of between 40,000 and 150,000 since such a polymer forms a solution of the desired viscosity in concentrations 0! the order of to and at a desirable spinning temperature.

In employing the evaporation method of spinning filaments and yarns in accordance with this invention, it is preferred to spin under vacuum to avoid the use of unduly high temperatures.

Shaped articles 01' acrylonitrile polymer can also be formed by extruding the spinning solution into a suitable precipitating bath comprising a liquid that is miscible with the solvent but is a chemically inert non-solvent for the acrylonitrile polymer. As examples oi such a liquid may be mentioned water, glycerin, organic solvents such as alcohol, ether, etc.. or aqueous solutions oi. salts, alkalies or acids. The copending application oi William W. Watkins Serial No. 496,376, filed July 28, 1043, covers the use of giveerol and aqueous solutions or salts or baths, preferably at elevated temperatures, for the wet spinning of acrylonitrile polymer yarn, from solutions of the polymer, preferably with substantial tension and stretch being applied during spinning.

The article of acrylonitrile polymer thus obtained can advantageously be subjected to a stretching operation or the type employed in the above examples. This stretching is preferably performed by passing the yarn between two positively driven rollers, the peripheral speeds of which are so adjusted that the article is stretched to from two to ten times its original length, preferably approximately six times its original length. This stretching of the formed article may be performed at any suitable time. However, in the case of articles formed by the wet spinplug or casting technique, it is preferably performed before the article has been completely dried. The orientation of the structure thus obtained greatly improves the physical properties of the structure including its tenacity, its resilience, etc.

This stretching oi the shaped article can also be accomplished by causing the article, while passing between stretching rollers, to contact a heated stationary pin, or to pass through an inert medium such as air, water, glycerin, etc., heated to a high temperature. Obviously, the article must not be exposed to this high temperature for a period sufficiently long to decompose the polymer. In general however, the time of contact of the article with the heated medium is so short that temperatures up to 250 C. can be employed. it is generally preferred to heat the article to a temperature of at least C. during the stretching operation. The stretching of acrylonitrile polymer, particularly under the influence 0! heat, is described and claimed in the copending application of Daniel T. Meloon Serial No. 496,397, filed July 28, 1943.

In addition to acting as solvents for polyacrylonitrile, or copolymers or interpolymers of acrylonitrile, the aromatic compounds of this invention. when present in small amounts, can also be used a plasticizing agents for the polymer and the higher boiling compounds oi the invention are especially suited for such use. At the same time, it is, of course, to be understood that non-solvent softeners such as glycerol, etc. can also be incorporated in the solutions of thi invention, these materials remaining in the subsequently formed articles to impart a softening effect. If it is desired to use such plasticizing or softening agents with polyacrylonltrile, they are preferably added in the desired amount to an already formed solution 01' the polymer in a lower boiling solvent.

This invention i primarily concerned with the steps of dissolving polyacrylonitrile in a suitable solvent to form a. stable solution adapted for use in the manufacture of shaped articles of polyderivatives of cellulose including cellulose ethers and esters, polymers of vinyl compounds such as vinyl chloride. vinyl acetate, acrylic acid. etc., which adiuvants may be incorporated in the acrylcnltrlle polymer solution to modify the properties, both chemical and P y ical. oi the resulting shaped articles.

This invention provides a class oi solvents for poiyacrylonitrile and copolymers and interpolymers of acrylonitrile, i. e. compounds which, when liquid, will form molecular dispersions containing an appreciable amount, e. g. or more by weight of the polymer. The invention also provides a class of materials that is eminently suited for use in plasticizing structures comprising the acrylonitrile polymers. The materials provided by this invention are apparently tr-ue solvents for the above-mentioned acrylonitrile polymers. They do not tend to react with or decompose the polymer. the polymeric material obtained irom the solution of this invention apparently being of the same identical chemical composition as the initial polymer.

Reference, throughout the specification and claims. to acrylonitrlle polymers, polymer of acrylonitrile. and copolymers and interpolymers oi acrylonitrile containing at least 85% by weight of acrylonitrile" signifies Polymers containing in their molecules at least 05% by weight of the acrylonitrile unit which is considered to be present in the polymer molecule as the group that is. at least 85% by weight of the reactant material converted into and forming the polymer is acrylonitrile.

Since it is obvious that many changes and modifications can be made in the above described details without departing from the nature and spirit of the invention. it is to be understood that the invention is not to be limited to the details described herein except as set forth in the appended claims.

I claim:

1. As a new composition of matter. a polymer of acrylonitrlle containing in the polymer molecule at least by weight oi. acrylonitrile dissolved in an aromatic compound taken from the group consisting oi Ortho phenylene diamine Meta phenylene diamine Para phenylene diamine 2 '-tetramino 5,5'-dimethyl dlphenyl methane 4,4'-diamino benzophenone 2.6-diamino pyridine 2. -triamino toluene.

2. A new composition 0! matter as defined in 351m 1, in which said polymer is poly cryloni- 3. A new composition of matter as defined in claim 1, in which said polymer of acrylonitrile is nonreactive with said aromatic compound.

4. A new composition of matter as defined in claim 1, in which said polymer has a molecular weight oi between 15,000 and 250,000.

5. A new composition of matter as defined in claim 1, in which said polymer has a molecular weight of between 40,000 and 150,000.

6. As a new composition of matter, a polymer of acrylonitrile containing in the polymer molecule at least 85% by weight of acrylonitrile and an aromatic compound taken from the groupconsistingot:

Orthc phenylene diamine Meta phenylene diamine Para phenyiene diamine 2,2',4,4'-tetramino 5,5-dimethyi diphenyl methane 4,4'-diamino benzophenone 2.6-diamino pyridine 2,4,8-triamino toluene.

7. The composition oi claim 1 in which the solution contains at least 10% of said polymer oi acrylonitrile.

8. The composition of claim 1 in which the solution has a viscosity within the range 25 to 'ltopoisec.

9. The composition 01' claim 1 in which the polymer is polyacrylcnitrile having a molecular weight of between 15,000 and 250,000.

10. The composition of claim 1 in which the polymer is polyacrylonitrile having a molecular weight of between 40,000 and 150,000.

RAY CLYDE HOUIZ.

Certificate of Correction Patent No. 2,404,720.

numbered atent requ and that t c said Letters July 2a, 1946.

RAY CLYDE HOUTZ It is hereby certified that error appears in the printed s correction as follows: Column 6, me 14, for "or read as; atent should be read with this correction therein that the ecification of the above same may coniorm to the record of the ease in the Patent Oifice. Signed and scaled this 15th day of October, A. D. 1946.

LESLIE FRAZER,

First Assistant Omission" of Patents.

7 acrylonitrlle. It is characteristic oi the invention that the solvents do not cause a decomposition or chemical alteration of the dissolved acrylonitrile polymer. At the same time, it is also characteristic that the solvents provided by the invention are also useful in the dissolving 01' mixtures of polyacrylonitrile and adjuvants such as dye modifiers. linear polyamides such as nylon,

derivatives of cellulose including cellulose ethers and esters, polymers of vinyl compounds such as vinyl chloride. vinyl acetate, acrylic acid. etc., which adiuvants may be incorporated in the acrylcnltrlle polymer solution to modify the properties, both chemical and P y ical. oi the resulting shaped articles.

This invention provides a class oi solvents for poiyacrylonitrile and copolymers and interpolymers of acrylonitrile, i. e. compounds which, when liquid, will form molecular dispersions containing an appreciable amount, e. g. 5% or more by weight of the polymer. The invention also provides a class of materials that is eminently suited for use in plasticizing structures comprising the acrylonitrile polymers. The materials provided by this invention are apparently tr-ue solvents for the above-mentioned acrylonitrile polymers. They do not tend to react with or decompose the polymer. the polymeric material obtained irom the solution of this invention apparently being of the same identical chemical composition as the initial polymer.

Reference, throughout the specification and claims. to acrylonitrlle polymers, polymer of acrylonitrile. and copolymers and interpolymers oi acrylonitrile containing at least 85% by weight of acrylonitrile" signifies Polymers containing in their molecules at least 05% by weight of the acrylonitrile unit which is considered to be present in the polymer molecule as the group that is. at least 85% by weight of the reactant material converted into and forming the polymer is acrylonitrile.

Since it is obvious that many changes and modifications can be made in the above described details without departing from the nature and spirit of the invention. it is to be understood that the invention is not to be limited to the details described herein except as set forth in the appended claims.

I claim:

1. As a new composition of matter. a polymer of acrylonitrlle containing in the polymer molecule at least by weight oi. acrylonitrile dissolved in an aromatic compound taken from the group consisting oi Ortho phenylene diamine Meta phenylene diamine Para phenylene diamine 2 '-tetramino 5,5'-dimethyl dlphenyl methane 4,4'-diamino benzophenone 2.6-diamino pyridine 2. -triamino toluene.

2. A new composition 0! matter as defined in 351m 1, in which said polymer is poly cryloni- 3. A new composition of matter as defined in claim 1, in which said polymer of acrylonitrile is nonreactive with said aromatic compound.

4. A new composition of matter as defined in claim 1, in which said polymer has a molecular weight oi between 15,000 and 250,000.

5. A new composition of matter as defined in claim 1, in which said polymer has a molecular weight of between 40,000 and 150,000.

6. As a new composition of matter, a polymer of acrylonitrile containing in the polymer molecule at least 85% by weight of acrylonitrile and an aromatic compound taken from the groupconsistingot:

Orthc phenylene diamine Meta phenylene diamine Para phenyiene diamine 2,2',4,4'-tetramino 5,5-dimethyi diphenyl methane 4,4'-diamino benzophenone 2.6-diamino pyridine 2,4,8-triamino toluene.

7. The composition oi claim 1 in which the solution contains at least 10% of said polymer oi acrylonitrile.

8. The composition of claim 1 in which the solution has a viscosity within the range 25 to 'ltopoisec.

9. The composition 01' claim 1 in which the polymer is polyacrylcnitrile having a molecular weight of between 15,000 and 250,000.

10. The composition of claim 1 in which the polymer is polyacrylonitrile having a molecular weight of between 40,000 and 150,000.

RAY CLYDE HOUIZ.

Certificate of Correction Patent No. 2,404,720.

numbered atent requ and that t c said Letters July 2a, 1946.

RAY CLYDE HOUTZ It is hereby certified that error appears in the printed s correction as follows: Column 6, me 14, for "or read as; atent should be read with this correction therein that the ecification of the above same may coniorm to the record of the ease in the Patent Oifice. Signed and scaled this 15th day of October, A. D. 1946.

LESLIE FRAZER,

First Assistant Omission" of Patents. 

